SECTION 4D1 - DIFFERENTIAL (FRONT) (MY2002)
Service Precaution
Front Drive Axle
Diagnosis
Pinion Shaft Oil Seal
Pinion Shaft Oil Seal and Associated Parts
Removal
Inspection and Repair
Installation
Front Drive Axle Assembly
Front Drive Axle Assembly
and Associated Parts
Removal
Installation
Differential Assembly
Disassembled View
Disassembly
Reassembly
Differential Cage Assembly
Disassembled View
Disassembly
Inspection and Repair
Reassembly
Main Data and Specifications
Special Tools
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
HOLDEN will call out those fasteners that require a
replacement after removal. HOLDEN will also call
out the fasteners that require thread lockers or
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fasteners. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.
Techline
Front Drive Axle
Diagnosis
Condition Possible cause Correction
Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal.
Front axle housing cracked. Repair or replace.
Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.
Oil seal worn or defective. Replace the oil seal.
Pinion flange loose or damaged. Tighten or replace.
Noises In Front Axle Drive Shaft
Joint
Broken or worn drive shaft joints and
bellows (BJ and DOJ).
Replace the drive shaft joints and
bellows.
“Clank" When Accelerating From
“Coast"
Loose drive shaft joint to output
shaft bolts.
Tighten.
Damaged inner drive shaft joint. Replace.
Shudder or Vibration During
Acceleration
Excessive drive shaft joint angle. Repair.
Worn or damaged drive shaft joints. Replace.
Sticking spider assembly (inner
drive shaft joint).
Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).
Lubricate or replace.
Vibration At Highway Speeds Out of balance or out of round tyres. Balance or replace.
Front end out of alignment. Align.
Noises in Front Axle Insufficient gear oil. Replenish the gear oil.
Wrong or poor grade gear oil. Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.
Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.
Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn. Replace the pinion shaft bearing.
Wheel bearing worn. Replace the wheel bearing.
Differential bearing loose or worn. Tighten or replace.
Wanders and Pulls Wheel bearing preload too tight. Adjust the wheel bearing preload.
Incorrect front alignment. Adjust the front alignment.
Steering unit loose or worn. Tighten or replace.
Tyre worn or improperly inflated. Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.
Tighten or replace.
Front Wheel Shimmy Wheel bearing worn or improperly
adjusted.
Adjust or replace.
Incorrect front alignment. Adjust the front alignment.
Worn ball joint or bush. Replace the ball joint or bush.
Steering unit loose or worn. Tighten or replace.
Tyre worn or improperly inflated. Replace or adjust the inflation.
Shock absorber worn. Replace the shock absorber.
Pinion Shaft Oil Seal
Pinion Shaft Oil Seal and Associated Parts
415R100002
Legend
EndOFCallout
Removal
1. Raise the vehicle and support it at the frame.
The hoist must remain under the front axle housing.
2. Drain the front axle oil by loosening the drain
plug(1).
412RS001
(1) Flange Nut
(2) Flange
(3) Oil Seal
(4) Outer Bearing
(5) Collapsible Spacer
3.Remove the front propeller shaft. Refer to Front
Propeller Shaft in this section.
4.Remove flange nut by using pinion flange holder 5–
8840–0133–0.
415RW040
5.Remove flange.
6.Remove oil seal.
7.Remove outer bearing by using remover 5–8840–
2323–0.
415RW048
8.Remove collapsible spacer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
1.Seal surface of the pinion.
2.Cage bore for burns.
Installation
1.Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2.Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the
outer bearing by hand, which should be indirectly
pressed in finally by tightening the flange nut.
3.Install oil seal, use oil seal installer 9–8522–1275–0
to install a new oil seal that has grease on seal lip.
415RW021
4.Install flange.
5.Install flange nut, refer to Differential Assembly
Overhaul for flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.
Front Drive Axle Assembly
Front Drive Axle Assembly and Associated Parts
412R200016
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EndOFCallout
(1) Propeller Shaft
(2) Mounting Nut
(3) Front Axle Case Assembly and Front Drive
Shaft Assembly
(4) Washer
(5) Mounting Bolt
(6) Tie–rod End; Power Steering Unit
(7) Knuckle and Back Plate
(8) Hub and Disc Assembly
(9) Suspension Crossmember
Removal
1.Jack up the vehicle and support it using jack stand.
2.Remove the tyre and wheel.
3.Remove the stone guard.
4.Remove the brake caliper fixing bolt and hang the
caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake
section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7.Remove the propeller shaft, refer to Front Propeller
Shaft in this section.
8.Loosen the height control arm of the torsion bar,
then remove the torsion bar from lower control arm.
refer to Torsion Bar in Suspension section.
9.Remove the suspension crossmember.
10.Remove the lower nut (1) of the stabilizer link.
11.Remove the lower bolt and nut (2) of the shock
absorber.
412RW057
12.Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Section 9A.
13.Disconnect the hose of the shift on the fly, at the
hose clip portion (1).
14.Disconnect the shift switch connector (2).
15.Remove the bolts and nuts of the lower control arm
(Frame side), then disconnect the lower control arm
from frame.
16.Disconnect between the right side upper control arm
and the knuckle, then remove the knuckle with lower
control arm.
CAUTION: When removing the knuckle, be careful
not to damage the oil seal inside of the knuckle.
410R200003
17.Support the differential case by the jack.
18.Remove the front axle mounting bolts and nuts,
lower the jack slowly. Remove the left side drive
shaft end from the knuckle, then lower the axle
assembly from the vehicle.
CAUTION:
1.During the work, be sure that the axle assembly
is supported securly.
2.Be careful not to damage the bellows of the
power steering unit by interference.
3.Be careful not to damage the hose bracket of the
shift on the fly by interference.
Installation
1.Support the differential case by the jack.
2.Jack up the front drive axle assembly, install the left
side drive shaft to the knuckle, then install the mount
bolts and nuts.
CAUTION:
1. Be careful not to damage the bellows of the
power steering unit by interference.
2. Be careful not to damage the hose bracket of the
shift on the fly by interference.
3. When installing the drive shaft to the knuckle,
be careful not to damage the oil seal inside of
the knuckle.
3.Tighten the mounting bolts and nuts to the specified
torque.
Torque:168N·m (17.2kg·m/124 lbft)
412RX011
4.Install the right side knuckle with lower control arm
to the upper control arm.
Refer to Knuckle in Section 3.
CAUTION: When insert the drive shaft to the
knuckle, be careful not to damage the oil seal inside
of the knuckle.
5.Align the bolt hole of the lower control arm, install
the bolts and nuts.
NOTE: Adjust the buffer clearance before tighten the
bolts and nuts of the lower control arm.
6.Install the hose of the shift on the fly (1).
7.Install the shift switch connector (2) of the shift on
the fly.
8.Install the tie-rod end of the power steering unit to
the knuckle, tighten the nut to the specified torque.
Torque:118N·m (12.0kg·m/87 lbft)
9.Install lower bolts and nuts of the shock absorber,
tighten it to the specified torque.
Torque:93N·m (9.5kg·m/69 lbft)
10.Install lower nuts of the stabilizer link, tighten it to
the specified torque.
Torque:50N·m (5.1kg·m/37 lbft)
11.Install the suspension crossmember.
12.Install the torsion bar.
Refer to Torsion Bar in Section 3.
13.Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14.Install the hub and disc assembly and adjust the
bearing preload.
Refer to Front Hub and Disc in this section.
15.Install the wheel speed sensor of the antilock brake
system.
16.Install the brake caliper. Tighten the bolt of the
caliper bracket to the specified torque.
Torque:155N·m (15.8kg·m/115 lbft)
17.Install the stone guard.
18.Install the tyre and wheel.
19.Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Section 9A.
20.Tighten the bolts and nuts of the lower control arm
to the specified torque.
Refer to Lower Control Arm in Section 3.
Differential Assembly
Disassembled View
415R200007
Legend
EndOFCallout
(1) Differential Assembly
(2) Flange Nut
(3) Flange
(4) Oil Seal
(5) Outer Bearing
(6) Outer Bearing Outer Race
(7) Differential Carrier
(8) Bearing Cap
(9) Bolt
(10) Collapsible Spacer
(11) Inner Bearing Outer Race
(12) Inner Bearing
(13) Adjust Shim
(14) Pinion Gear
(15) Diff Cage Assembly
(16) Side Bearing Outer Race
(17) Side Bearing
(18) Adjust Shim
(19) Bolt
(20) Axle Case
Disassembly
1. Remove differential carrier fixing bolt.
2. Remove differential assembly.
3. Using holding fixture 5–8840–0275–0 and holding
fixture base 5–8840–0003–0, fix the differential
assembly to the bench.
425RW046
4. Remove bearing cap bolt.
5. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
425RS009
6. Remove differential cage assembly.
7. Remove side bearing outer race, after removal,
keep the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
8. Remove side bearing, using remover 5–8840–
2587–0 and adapter 5–8840–2576–0.
• Select insert; 303173 and collet halves; 44801 in
remover kit 5–8840–2587–0.
415RW041
9. Remove adjust shim, note the thickness and
position of the shims removed.
10. Remove the flange nut using holding wrench 5–
8840–0133–0.
415RW040
11. Remove flange using an universal puller.
12. Remove the drive pinion assembly using a soft
metal rod and a hammer.
425RS012
13. Remove collapsible spacer.
14. Remove the inner bearing using remover 5–8840–
2587–0.
• Select insert; 303173 and collet halves; 44801 in
remover kit 5–8840–2587–0.
415RW042
15. Remove adjust shim.
16. Remove oil seal.
17. Remove oil seal slinger.
18. Remove outer bearing.
19. Remove the inner bearing outer race (1) and the
outer bearing outer race (2) by using a brass bar
and a hammer.
425RS014
425RS015
Reassembly
1. Using installer 9–8522–1141–0 and grip 5–8840–
0007–0, install outer bearing outer race.
415RW018
2. Using installer 9–8522–1274–0 and grip 5–8840–
0007–0, install Inner bearing outer race.
415RW017
3. Install adjust shim and adjust drive pinion mounting
distance:
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the
inner and outer bearings.
2. Tighten the nut to the specified torque.
Torque:2.3N·m (0.2kg·m/20 lbin)
415RS009
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EndOFCallout
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Torque:98N·m (10kg·m/72lbft)
415RS010
Legend
EndOFCallout
(1) Pilot : 5–8840–2085–0
(2) Nut and Bolt: 5–8840–2089–0
(3) Gauge Plate : 5–8840–2087–0
(1) Dial Indicator: 5–8840–0126–0
(2) Disc (2 pcs.): 5–8840–2088–0
(3) Arbor: 5–8840–0128–0
(4) Gauge Plate: 5–8840–2087–0
4. Set the dial indicator to “0". Place it on the
mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the
dial indicator in this position.
425RS020
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EndOFCallout
5. Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicator
shows the greatest defection. At this point, once
again set the dial indicator to “0".
Repeat the procedure to verify the “0" setting.
425RS021
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does
not touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
Legend
EndOFCallout
7. Record the pinion depth code on the head of the
drive pinion.
The number indicates a necessary change in
the pinion mounting distance. A plus number
indicates the need for a greater mounting
distance (which can be achieved by decreasing
the shim thickness). A minus number indicates
the need for a smaller mounting distance (which
can be achieved by increasing the shim
thickness). If examination reveals pinion depth
code “0", the pinion is “nominal".
425RS023
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
(1) Example=Dial indicator reading of 0.085
8. Select the shim using chart;
NOTE: When ordering shims, find the part number in
the parts catalog by using the thickness of shims listed
in the ablve table.
Pinion
marking +10+8+6+4+2 0 –2–4–6–8–10
Dial
indicator
reading
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
mm
(Inches)
0.081 2.18
(0.0858)
0.082 2.18
(0.0858)
2.20
(0.0866)
0.083 2.18
(0.0858)
2.20
(0.0866)
2.23
(0.0882)
0.084 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
0.085 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
0.086 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
0.087 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
0.088 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
0.089 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
0.090 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
0.091 2.18
(0.0858)
2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
0.092 2.20
(0.0866)
2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
0.093 2.24
(0.0882)
2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
0.094 2.26
(0.0890)
2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
0.095 2.28
(0.0898)
2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
0.096 2.32
(0.0914)
2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.097 2.34
(0.0921)
2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.098 2.36
(0.0929)
2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.099 2.38
(0.0937)
2.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
02.42
(0.0953)
2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.001 2.44
(0.0961)
2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.002 2.46
(0.0969)
2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.003 2.48
(0.0977)
2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.004 2.52
(0.0992)
2.54
(0.1000)
2.56
(0.1008)
0.005 2.54
(0.1000)
2.56
(0.1008)
0.006 2.56
(0.1008)
4. Place the shim on the drive pinion. Install the inner
bearing onto the pinion using an installer 9–8522–
1165–0 and a press.
NOTE: Do not apply pressure to the roller cage and
apply pressure only to the inner race.
425RW067
5. Discard the used collapsible spacer and install a
new one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer 9–8522–1275–0 to install a
new oil seal that has been soaked in front axle
lubricant.
NOTE: Take care to use a front differential oil seal,
NOT the rear differential oil seal.
415RW024
9. Install flange.
10. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder 5–8840–0133–0.
Torque:177-275 N·m(18-28kg·m/130-203lbft)
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
415RW006
3. Adjust pinion bearing preload.
a Measure the bearing preload by using a
torque meter. Note the scale reading
required to rotate the flange.
b Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing:0.7–1.1N·m(6.5–11.5kg·cm/5.6–
10lbin)
Used bearing:0.4–0.5N·m(3.3–5.7kg·cm/2.9–
5.0lbin)
425RS027
4. Using punch 5–8840–2293–0, stake the flange
nut at two points.
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3)
415RW019
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EndOFCallout
11. Install adjust shim.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
425RS029
Legend
EndOFCallout
2. Insert the differential cage assembly with
bearing outer races into the side bearing bores
of the carrier.
425RS030
(1) 1.3mm or less
(1) Drive handle:5–8840–0007–0
(2) Installer:9–8522–1164–0
(3) Pilot:9–8521–1743–0
3. Using two sets of feeler gauges, insert a feeler
stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is
pushed to the bottom of the bearing bores.
Mount the dial indicator 5–8840–0126–0 on the
carrier so that the indicator stem is at right
angles to a tooth on the ring gear.
425RS031
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash:0.13–0.18mm(0.005 –0.007in)
425RS032
With zero end play and correct backlash
established, remove the feeler gauge packs,
determine the thickness of the shims required
and add 0.05 mm (0.002 in) to each shim pack
to provide side bearing preload. Always use new
shims.
5. Use bearing remover 5–8840–2587–0 and pilot
5–8840–2576–0 to remove side bearing.
• Select insert; 303173 and collet halves;44801
in remover kit 5–8840–2587–0.
415RW041
12. Install the side bearings together with the selected
shims.
425RS029
Legend
EndOFCallout
(1) Drive Handle:5–8840–0007–0
(2) Installer: 9–8522–1164–0
(3) Pilot: 9–8521–1743–0
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035
16. Tighten the cap bolt to the specified torque.
Torque:98N·m (10kg·m/72lbft)
425RS036
1. Measure the amount of run-out of the ring gear
at its rear face.
Standard: 0.02 mm (0.001 in)
Limit: 0.05 mm (0.002 in)
425RS037
Gear Tooth Contact Pattern Check and
Adjustment
1. Apply a thin coat of prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring
gear teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.
425RS038
Legend
EndOFCallout
425RS039
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
17. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
Torque:25 N·m (2.5kg·m/19 lb ft)
415RS014
3. Fill the axle case with hypoid gear lubricant, to
just below the filler hole.
Lubricant capacity:1.25liter(1.1 Imp qt/1.32 US qt)
Differential Cage Assembly
Disassembled View
415RS015
Legend
EndOFCallout
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin,
using a 5mm (0.20 in) diameter drill.
425RS042
(1) Pinion Gear
(2) Thrust Washer
(3) Side Gear
(4) Cross Pin
(5) Ring Gear
(6) Bolt
(7) Differential Cage
(8) Lock Pin
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt.
4. Discard used bolts and install new ones..
Torque:108 N·m (11.0Kg·m/80 lb ft)
415RS016
Clearance between the differential pinion
and the cross pin measurement:
Standard: 0.06 - 0.12 mm (0.002 - 0.005 in)
Limit: 0.2 mm (0.008 in)
425RS045
Clearance between the side gear and the
differential box:
Standard: 0.03 - 0.10 mm (0.001 - 0.004 in)
Limit: 0.15 mm (0.006 in)
425RS046
Legend
EndOFCallout
Play in splines between the side gear and
the axle shaft:
Standard: 0.08 - 0.36 mm (0.003 - 0.014 in)
Limit: 0.5 mm (0.02 in)
425RS047
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by
engaging it with the side gears while turning both
pinion gears simultaneously in the same direction.
425RS048
4. Install cross pin.
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
(1) Side Gear
(2) Differential Box
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash: 0.03 - 0.08 mm (0.001 - 0.003 in)
Thickness of thrust washers available:
1.00mm, 1.05mm, 1.10mm(0.039 in, 0.041in,
0.043in)
425RS050
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
425RS051
Legend
EndOFCallout
6. Clean the ring gear threaded holes to remove the
locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.
7. Tighten the bolts in diagonal sequence as
illustrated.
Torque: 108 N·m (11.0kg·m/80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016
(1) Staked Portion
(2) Lock Pin
Main Data and Specifications
General Specifications
Axle tube Type It consists of the duct, a cast iron housing and the axle
tube.
Gear type Hypoid
Gear ratio (to 1) 4.100 (6VD1 with A/T)
4.300 (6VD1 with M/T)
Differential type Two pinion
Oil capacity liter (US qt) 1.25 (1.32) (Differential)
0.12 (0.13) (Actuator Housing: Shift on the fly)
Type of lubricant GL–5 (75W–90)
Axle shaft type Constant velocity joint (Birfield joint type and double offset
joint)
Hub locking Type Rigid
Torque Specifications
412R100002
415R200008
Special Tools
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–0133–0
(J–8614–01)
Holder; Pinion flange
9–8522–1275–0
(J–24250)
Installer; Oil seal
5–8840–0275–0
(J–37264)
Differential holding fixture
(Use with 5–8840–0003–
0 base)
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–2587–0
(J–42379)
Remover; Side Pinion/
bearing
9–8521–1743–0
(J–8107–2)
Adapter; Side bearing
plug
9–8522–1141–0
(J–24256)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Driver handle
9–8522–1274–0
(J–24252)
Installer; Inner bearing
outer race
5–8840–2085–0
(J–21777–42)
Pilot
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–2089–0
(J–23597–9)
Nut and bolt
5–8840–2087–0
(J–23597–7)
Gauge plate
5–8840–0126–0
(J–8001)
Dial indicator
5–8840–2088–0
(J–23597–8)
Disc
5–8840–0128–0
(J–23597–1)
Arbor
9–8522–1165–0
(J–6133–01)
Installer; Pinion bearing
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–2293–0
(J–39209)
Punch; End nut lock
9–8522–1164–0
(J–24244)
Installer; Side bearing
5–8840–2323–0
(J–39602)
Remover; Outer bearing
ILLUSTRATION TOOL NO.
TOOL NAME